Energy absorber for sensor protection

ABSTRACT

A vehicle includes: a bumper beam; an electronic sensor that is fixed in relation to the bumper beam; and an energy absorber that is connected to the bumper beam in general alignment with the electronic sensor. The energy absorber is configured and positioned to protect the electronic sensor and reduce dislocation of the electronic sensor by absorbing energy resulting from a low-force impact between the vehicle and an external object (e.g., another vehicle). The energy absorber may be provided in the front and/or rear-ends of the vehicle, and, in certain embodiments, may be connected to an end face of the bumper beam (e.g., to a front face or a rear face of the bumper beam) such that the energy absorber is positioned outwardly (e.g., forwardly or rearwardly) of the electronic sensor along a length of the vehicle.

TECHNICAL FIELD

The present disclosure relates generally to vehicles, and, morespecifically, to energy absorbers that are positioned to mitigate damageto, and/or dislocation of, one or more sensors in vehicles.

BACKGROUND

Many vehicles include one or more sensors (e.g., radar sensors,emergency braking sensors, intelligent cruise control sensors,pedestrian sensors, etc.) located at the front-end and/or the rear-endof the vehicle. For example, such sensors are often mounted to, orotherwise associated with, the front and/or rear bumpers of the vehicle.During low-force impacts, these sensors can be damaged, dislocated, orotherwise disturbed. To address such issues, the present disclosuredescribes energy absorbers that are configured and positioned to absorbforces, shock, etc. that might otherwise be communicated to the sensorsand/or the sensor mounts.

SUMMARY

In one aspect of the present disclosure, a vehicle is disclosed thatincludes: a bumper beam; an electronic sensor that is fixed in relationto the bumper beam; and an energy absorber that is connected to thebumper beam in general alignment with the electronic sensor. The energyabsorber is configured and positioned to protect the electronic sensorand reduce dislocation of the electronic sensor by absorbing energyresulting from a low-force impact between the vehicle and an externalobject.

In certain embodiments, the energy absorber is connected to an end faceof the bumper beam (e.g., a front face or a rear face of the bumperbeam) such that the energy absorber is positioned outwardly (e.g.,forwardly or rearwardly) of the electronic sensor.

In certain embodiments, the electronic sensor and the energy absorbermay each define a width that extends in generally parallel relation tothe bumper beam, wherein the width of the energy absorber is greaterthan or equal to the width of the electronic sensor.

In certain embodiments, the energy absorber may include a foam having adensity greater than 10 pcf.

In certain embodiments, the energy absorber may include at least onebrace that is configured for contact with the bumper beam to verticallysupport the energy absorber.

In certain embodiments, the energy absorber may include a body having anon-uniform cross-sectional configuration.

In certain embodiments, the body of the energy absorber may include agenerally L-shaped (non-uniform) cross-sectional configuration.

In certain embodiments, the energy absorber may be configured as abracket. In such embodiments, the bracket may include a first end wall,a pair of side walls that extend from the first end wall, and an openinterior region to allow for deformation of the energy absorber duringthe low-force impact.

In certain embodiments, the bracket may further include a second endwall that connects the side walls. In such embodiments, the second endwall may include a mounting structure to facilitate connection of thebracket to the bumper beam.

In certain embodiments, the bracket may further include a pair offlanges that extend from the side walls. In such embodiments, theflanges may be oriented in generally parallel relation to the first endwall and may each include a mounting structure to facilitate connectionof the bracket to the bumper beam.

In certain embodiments, the energy absorber may include a firstabsorption member and a second absorption member that is connected tothe first absorption member. In such embodiments, the first absorptionmember may include (e.g., may be formed from) a first material, and thesecond absorption member may include (e.g., may be formed from) a secondmaterial that is different from the first material. For example, thefirst material may be metallic, and the second material may include afoam.

In another aspect of the present disclosure, a vehicle is disclosed thatincludes a bumper beam; an electronic sensor that is fixed in relationto the bumper beam; and an energy absorber that is connected to an endface of the bumper beam (e.g., a front face or a rear face of the bumperbeam) such that the energy absorber is positioned outwardly (e.g.,forwardly or rearwardly) of the electronic sensor along a length of thevehicle and in general alignment with the electronic sensor. The energyabsorber includes a foam body that is configured and positioned toabsorb energy during a low-force impact between the vehicle and anexternal object to protect the electronic sensor and reduce dislocationof the electronic sensor.

In certain embodiments, the electronic sensor and the energy absorbermay be centrally positioned in relation to the bumper beam.

In certain embodiments, the electronic sensor and the energy absorbermay each define a width that extends in generally parallel relation tothe bumper beam, wherein the width of the energy absorber is greaterthan or equal to the width of the electronic sensor.

In certain embodiments, the foam body may include an expandedpolypropylene foam having a density greater than 10 pcf.

In certain embodiments, the foam body may include a generally L-shaped(non-uniform) cross-sectional configuration.

In another aspect of the present disclosure, a method is disclosed forprotecting an electronic sensor in a vehicle during a low-force impactbetween the vehicle and an external object. The method includes securingan energy absorber to a bumper beam of the vehicle such that the energyabsorber is positioned outwardly of the electronic sensor and in generalalignment with the electronic sensor, wherein the energy absorberdefines a width extending in generally parallel relation to the bumperbeam that is greater than or equal to a width of the electronic sensor.

In certain embodiments, securing the energy absorber to the bumper beammay include positioning a foam body of the energy absorber verticallybelow the electronic sensor.

In certain embodiments, securing the energy absorber to the bumper beammay include connecting a bracket to the bumper beam. In suchembodiments, the bracket may include an open interior region to allowfor deformation of the bracket during the low-force impact.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawings maynot be to scale and may be arbitrarily expanded or reduced for clarity.

FIG. 1 is a partial, front, perspective view illustrating the front-endof a vehicle including a sensor and one embodiment of an energy absorbershown mounted to a bumper beam of the vehicle;

FIG. 2 is a partial, cross-sectional view of the front-end of thevehicle and the energy absorber seen in FIG. 1;

FIG. 3 is a partial, front, perspective view illustrating the front-endof the vehicle with an alternate embodiment of the energy absorber;

FIG. 4 is a rear, perspective view of the energy absorber seen in FIG.3;

FIG. 5 is a partial, cross-sectional view of the front-end of thevehicle shown with the energy absorber seen in FIG. 4;

FIG. 6 is a partial, front, perspective view illustrating the front-endof the vehicle with an alternate embodiment of the energy absorber;

FIG. 7 is a partial, cross-sectional view of the front-end of thevehicle shown with the energy absorber seen in FIG. 6;

FIG. 8 is a partial, front, perspective view illustrating the front-endof the vehicle with another embodiment of the energy absorber configuredas a bracket;

FIG. 9 is a partial, front view illustrating the front-end of thevehicle and the energy absorber seen in FIG. 8;

FIG. 10 is a partial, front, perspective view illustrating an alternateconfiguration for the bracket seen in FIGS. 8 and 9;

FIG. 11 is a partial, front, perspective view illustrating the front-endof the vehicle with another embodiment of the energy absorber includingfirst and second absorption members;

FIG. 12 is a partial, front, perspective view illustrating the front-endof the vehicle including another embodiment of the energy absorber;

FIG. 13 is a partial, side, perspective view illustrating the front-endof the vehicle and the energy absorber seen in FIG. 12; and

FIG. 14 is a partial, top view illustrating the front-end of the vehicleand the energy absorber seen in FIG. 12.

DETAILED DESCRIPTION

The present disclosure describes various embodiments of energy absorbersfor use with vehicles to absorb forces, shock, etc., during low-forceimpacts with external objects, such as other vehicles, structures, etc.,which may range from 2 mph to 5 mph (or more) depending upon the size,weight, and configuration of the external object(s). The presentlydisclosed energy absorber may be positioned in the front-end and/or therear-end of a vehicle (e.g., on an end face of the front and/or rearbumper beam) and are in general lateral alignment with the sensor(s)(i.e., along the width of the vehicle). The energy absorber may include(e.g., may be formed from) any suitable materials or combination ofmaterials, including, for example, metallic materials (e.g., aluminum,steel, etc.) and/or non-metallic materials (e.g., foam), and may besecured (e.g., to the bumper beam(s)) in any suitable manner, such as,for example, through the use of mechanical fasteners (e.g., screws,rivets, pins, clips, bolts, etc.), welds, adhesive(s), etc. Dependingupon the particular application and the particular vehicle in which theenergy absorber is employed, the configuration of the energy absorbermay be varied. For example, the energy absorber may include a uniform,generally polygonal (e.g., rectangular or square) cross-sectionalconfiguration, or the energy absorber may include a more complex,non-uniform cross-sectional configuration. For example, the energyabsorber may include a generally L-shaped cross-sectional configuration,or the energy absorber may be configured as a bracket defining an openinterior region to allow for deformation of the energy absorber duringlow-force impacts, and, thus, the absorption of energy.

FIGS. 1 and 2 illustrate the front-end of a vehicle V together with oneembodiment of an energy absorber (identified by the reference character100) in accordance with the principles of the present disclosure. Inrelevant part, the front-end of the vehicle V includes a bumper beam 10and an electronic sensor 12. The electronic sensor 12 may be any sensorsuitable for use in the front-end (or the rear-end) of the vehicle V,including, for example, a radar-based sensor (e.g., an emergency brakingsensor, an intelligent cruise control sensor, a pedestrian sensor,etc.). The electronic sensor 12 is supported by a mount 14 such that theelectronic sensor 12 is fixed in relation to the bumper beam 10 and maybe connected to the vehicle V in any suitable location. For example, inthe particular embodiment of the vehicle V seen in FIGS. 1 and 2, themount 14 is connected to the vehicle V's battery charge port bracket 16.

The energy absorber 100 is fixed in relation to the bumper beam 10, andmay be secured thereto, either directly or indirectly (i.e., via anintervening structure), using any suitable mechanism, structure,element, or combination thereof. For example, in the embodiment seen inFIG. 1, the energy absorber 100 is fixedly connected to a (front) endface 18 of the bumper beam 10 (e.g., to the forward-most verticalsurface thereof) such that the energy absorber 100 is positionedoutwardly (i.e., forwardly) of the electronic sensor 12. When associatedwith a rear-end of the vehicle V, however, it should be appreciated thatthe energy absorber 100 would be likewise positioned in relation andfixedly connected to a rear-end face of a bumper beam similar oridentical to the bumper beam 10 (e.g., to the rearward-most verticalsurface thereof) located at the rear-end of the vehicle V.

The energy absorber 100 includes a housing 102 with opposite ends 104,106 defining lateral supports 108, 110 having apertures 112 that areconfigured to receive mechanical fasteners 114 (e.g., screws, rivets,pins, clips, bolts, etc.) that are insertable into correspondingopenings 20 formed in the bumper beam 10, either fixedly or removably.Additionally, or alternatively, it is envisioned that the energyabsorber 100 and the bumper beam 10 may include corresponding engagementmembers or surfaces (e.g., snaps, clips, hooks, etc.) that facilitateconnection of the energy absorber 100 to the bumper beam 10, such as,for example, in a snap-fit or interference-fit arrangement.

As seen in FIG. 1, the energy absorber 100 defines a width W1 that isgreater than or equal to a width W2 defined by the electronic sensor 12(each of which extends in generally parallel relation to the bumper beam10) and is oriented in general alignment with the electronic sensor 12.More specifically, the energy absorber 100 is oriented such that theelectronic sensor 12 is positioned between the ends 104, 106 of theenergy absorber 100. Although shown as being eccentrically mounted tothe bumper beam 10 (i.e., such that the energy absorber 100 is locatedoff-center with respect to the bumper beam 10) and below the electronicsensor 12 (i.e., closer to the ground), in alternate embodiments, it isenvisioned that the orientations of the energy absorber 100 and theelectronic sensor 12 may be varied. For example, depending upon theparticular location of the electronic sensor 12, the configuration ofthe bumper beam 10, spatial requirements, packaging concerns, etc., itis envisioned that the energy absorber 100 may be centrally mounted withrespect to the bumper beam 10, that the energy absorber 100 may bevertically aligned with the electronic sensor 12, or that the energyabsorber 100 may be positioned above the electronic sensor 12 (i.e.,such that the energy absorber 100 is further from the ground).

The energy absorber 100 may include (e.g., may be formed from) anymaterial or combination of materials suitable for the intended purposeof absorbing forces that may be otherwise communicated to the electronicsensor 12 during a low-force impact with the vehicle V, as discussed infurther detail below. For example, in the embodiment seen in FIGS. 1 and2, the energy absorber 100 includes a body 116 formed from a foam havinga density of 10 pcf or higher, such as an expanded polypropylene foam.Although shown as being positioned within the housing 102 in FIGS. 1 and2, in alternate embodiments of the disclosure, it is envisioned that thehousing 102 may be omitted, and that the body 116 may be directlyconnected to the bumper beam 10 through the use of mechanical fasteners(e.g., screws, rivets, pins, clips, bolts, etc.), adhesive(s), etc.

With continued reference to FIGS. 1 and 2, use and functionality of theenergy absorber 100 during a low-force impact between the vehicle V andan external object O (e.g., another vehicle, a shopping cart, a roadbarrier, etc.) will be discussed. Upon impact with the object O, force Fis applied to the vehicle V in the direction indicated in FIG. 2. Theenergy absorber 100, however, is configured and positioned in the pathof the force F to interrupt and absorb the force F, which wouldotherwise be communicated to the electronic sensor 12 and/or the bracketmount 14. By absorbing the force F, the energy absorber 100 therebyprotects the electronic sensor 12 to mitigate (if not entirely prevent)damage to the electronic sensor 12 and/or the mount 14, and limit (ifnot entirely prevent) dislocation (i.e., undesirable displacement) ofthe electronic sensor 12 and/or the mount 14 to thereby preserve thepositions thereof. The energy absorber 100 thus reduces the likelihoodof malfunction after the impact as well as the need for repair orreplacement of the electronic sensor 12 and/or the mount 14, and, assuch, the overall cost associated with ownership and operation of thevehicle V. By protecting the electronic sensor 12 and the mount 14, theenergy absorber 100 may also increase the likelihood that the vehicle Vwill remain in compliance with any applicable regulations and/or safetyrequirements following the impact.

With reference now to FIGS. 3-14, various alternate embodiments of theenergy absorber 100 will be discussed. Each of the embodiments discussedhereinbelow is substantially similar in both structure and function tothe energy absorber 100, and accordingly, in the interest of brevity,will be discussed only with respect to any differences therefrom.

FIGS. 3-5 illustrate an embodiment of the energy absorber identified bythe reference character 200. As seen in FIG. 3, the energy absorber 200is devoid of the lateral supports 108, 110 (FIG. 1) included on theenergy absorber 100. Instead, the energy absorber 200 includes one ormore wings (braces) 218 that extend towards the electronic sensor 12 andthe bumper beam 10. The wing(s) 218 may be formed from any suitablematerial and may be either discrete structures that are connected to thehousing 202 of the energy absorber 200 or may be integrally formedtherewith. For example, in certain embodiments, it is envisioned thatthe wing(s) 218 may be monolithically formed with the housing 202 (e.g.,via injection molding). The wing(s) 218 extend from an upper surface 220housing 202 along the length of the vehicle V in transverse (ororthogonal) relation to the width W1 of the energy absorber 200.Although shown as including a pair of wings 218 in the illustratedembodiment, in alternate embodiments of the disclosure, it is envisionedthat the number of wings 218 may be varied. For example, the energyabsorber 200 may include a single wing 218 only, or three or more wings218.

In the particular embodiment of the energy absorber 200 shown in FIGS.3-5, the energy absorber 200 is shown in association with the front-endof the vehicle V. As such, the wings extend rearwardly towards theelectronic sensor 12 and the bumper beam 10. When associated with therear-end of the vehicle V, however, it should be appreciated that thewing(s) 218 would extend towards the electronic sensor 12 and the bumperbeam 10 in the opposite direction (i.e., forwardly).

The wing(s) 218 extend beyond a (rear) end face 222 (FIGS. 4, 5) of theenergy absorber 200 (e.g., the housing 202) so as to define one or moreshoulders 224 that are configured for contact with an upper surface 22(FIG. 3) of the bumper beam 10 such that the bumper beam 10 supports thevertical position of the energy absorber 200. To further secure theenergy absorber 200 in relation to the bumper beam 10 (e.g., to restrictor prevent lateral movement of the energy absorber 200), it isenvisioned that the energy absorber 200 may include a boss 226 (FIGS. 4,5) that extends outwardly (i.e., rearwardly or forwardly) from thehousing 202 for positioning within a corresponding opening 24 defined inthe bumper beam 10. Additionally, or alternatively, it is envisionedthat the energy absorber 200 may be adhesively secured to the bumperbeam 10 (e.g., using one or more adhesive strips 228), as seen in FIG.4.

The energy absorber 200 may also include an additional support member230 (FIG. 4) to further maintain the horizontal and/or vertical positionof the energy absorber 200 in relation to the bumper beam 10. Forexample, as seen in FIG. 4, the support member 230 may be configured asa plate 232 that extends from the upper surface 220 of the housing 202of the energy absorber 200 along the length of the vehicle V and beyondthe (rear) end face 222 of the housing 202. The plate 232 includes oneor more openings 234 that are configured to receive mechanical fasteners236 (e.g., screws, rivets, pins, clips, bolts, etc.) such that themechanical fastener(s) extend into the bumper beam 10.

FIG. 6 illustrates another embodiment of the energy absorber, which isidentified by the reference character 300. In contrast to the energyabsorber 100 seen in FIGS. 1 and 2, which includes a generally polygonal(e.g., rectangular or square) cross-sectional configuration, the energyabsorber 300 includes a complex cross-sectional configuration. Morespecifically, the body 316 of the energy absorber 300 includes a rear(first) section 338 and a front (second) section 340 that extends(forwardly) from the rear section 338 such that the energy absorber 300includes a generally L-shaped cross-sectional configuration. Althoughillustrated as being monolithically formed in the embodiment of theenergy absorber 300 seen in FIG. 6, it is also envisioned that thesections 338, 340 may be formed separately and connected to one anotherin any suitable manner, such as, for example, via one or more mechanicalfasteners, adhesive, etc.

It is envisioned that the body 316 of the energy absorber 300 may beentirely formed from the aforementioned foam (e.g., expandedpolypropylene) such that the energy absorber 300 is uniform inconstruction. Alternatively, however, it is envisioned that the energyabsorber 300 may be non-uniform in construction and that the sections338, 340 may include (e.g., may be formed from), different materials.For example, it is envisioned that the front section 340 may be formedfrom a foam having a first density and that the rear section 338 may beformed from a foam having a second, different density (i.e., greaterthan or less than that of the front section 340).

Although shown and described as being devoid of a housing, in certainembodiments of the disclosure, it is envisioned that the energy absorber300 may further include such a housing (similar to the housings 102, 202discussed above in connection with the energy absorbers 100, 200,respectively) to accommodate the body 316.

FIG. 7 illustrates another embodiment of the energy absorber, which isidentified by the reference character 400. The energy absorber 400 isidentical to the energy absorber 300 but for the inclusion of one ormore wings 418, as discussed above in connection with the energyabsorber 200 seen in FIGS. 3-5.

With reference now to FIGS. 8 and 9, an embodiment of the energyabsorber will be described that is identified by the reference character500. The energy absorber 500 is configured as a bracket 542, and mayinclude (e.g., may be formed from) any suitable material or combinationof materials. For example, it is envisioned that the bracket 542 mayinclude one or more metallic materials, such as aluminum, steel, etc.,one or more plastics or polymeric materials, carbon fiber, etc., andthat the bracket 542 may be formed through any suitable manufacturingprocess.

The bracket 542 includes a front (first) end wall 544, a pair of sidewalls 546 i, 546 ii that extend from the front end wall 544 at anglesαi, αii, respectively, and flanges 548 i, 548 ii that extend from theside walls 546 i, 546 ii, respectively, in generally parallel relationto the front end wall 544. To facilitate connection of the energyabsorber 500 to the bumper beam 10, the flanges 548 i, 548 ii mayinclude engagement structures 550 i, 550 ii, respectively, which, in theillustrated embodiment, include a series of apertures 552 that areconfigured to receive one or more mechanical fasteners 554 (e.g.,screws, rivets, pins, clips, bolts, etc.). Additionally, oralternatively, it is envisioned that the bracket 542 (e.g., the flanges548 i, 548 ii) may be welded or adhesively secured to the bumper beam10, or that the flanges 548 i, 548 ii may be configured and dimensionedfor receipt within corresponding openings, slits, brackets, or othersuch structure included on (or formed in) the bumper beam 10. Forexample, it is envisioned that the bumper beam 10 may define pockets orthe like into which the flanges 548 i, 548 ii may be inserted (e.g.,from above).

The bracket 542 defines an open interior region 556 between the sidewalls 546 i, 546 ii that is positioned in general alignment with theelectronic sensor 12 in a manner consistent with the discussion aboveregarding the energy absorber 100 (FIGS. 1, 2). When subject to animpact, the open interior region 556 allows the energy absorber 500 toflex and/or deform to thereby absorb the force F (FIG. 2) that wouldotherwise be communicated to the electronic sensor 12 and/or the mount14 absent the energy absorber 500. In the embodiment seen in FIGS. 8 and9, the bracket 542 is configured such that the side walls 546 i, 546 iiform equivalent obtuse angles α with the front end wall 544 (e.g., toincrease the force-absorption capabilities of the bracket 542). Invarious embodiments of the disclosure, however, the particularorientation of the side walls 546 i, 546 ii may be varied to alter theangles αi, αii. For example, the side walls 546 i, 546 ii may bearranged so as to increase or decrease the angles αi, αii. It is alsoenvisioned that, in certain embodiments, the side walls 546 i, 546 iimay extend from the front end wall 544 such that the angles αi, αii aredissimilar.

Although the bracket 542 is configured such that the front end walls 544and the side walls 546 i, 546 ii define equivalent thicknesses T in theembodiment seen in FIGS. 8 and 9, in alternate embodiments of thedisclosure, it is envisioned that the thickness T may be varied betweenthe front end wall 544 and the side walls 546 i, 546 ii. For example,the thickness T of the front end wall 544 may be greater than (or lessthan) the thickness T of the side wall 546 i and/or the side wall 546 iito promote deformation of the bracket 542 in a particular manner. It isalso envisioned that one or more of the front end wall 544 and the sidewalls 546 i, 546 ii may include one or more weakened portions (e.g.,reliefs, openings, slits, etc.) to promote controlled deformation of thebracket 542.

FIG. 10 illustrates another embodiment of the energy absorber, which isidentified by the reference character 600. The energy absorber 600 isconfigured as a bracket 642 similar to the bracket 542 discussed abovewith respect to FIGS. 8 and 9. However, in addition to a front (first)end wall 644 and a pair of side walls 646 i, 646 ii, the bracket 642further includes a rear (second) end wall 658 such that the end walls644, 646 extend between and connect the side walls 646 i, 646 ii.Although shown as including a generally rectangular cross-sectionalconfiguration, in alternate embodiments of the disclosure, it isenvisioned that the particular dimensions and arrangement of the endwalls 644, 658 and the side walls 646 i, 646 ii may be varied so as tovary the cross-sectional configuration of the bracket 642. For example,the front end wall 644 may define a width W3 less than a width W4 of therear end wall 658 such that the side walls 646 i, 646 ii extend from thefront end wall 644 at angles αi, αii, respectively, greater than 90°, asdiscussed above in connection with FIGS. 8 and 9. Alternatively, thewidth W3 of the front end wall 644 may exceed the width W4 of the rearend wall 658 such that the angles αi, αii are less than 90°.

As discussed above in connection with the energy absorber 500, thebracket 642 defines an open interior region 656 that is positioned ingeneral alignment with the electronic sensor 12 to allow the energyabsorber 600 to flex and/or deform to thereby absorb the force F (FIG.2) that would otherwise be communicated to the electronic sensor 12and/or the mount 14 in the absence of the energy absorber 600.

To facilitate connection of the energy absorber 600 to the bumper beam10, the energy absorber 600 includes one or more engagement structures650. In the illustrated embodiment, for example, the engagementstructures 650 include a series of apertures 652 formed in the end walls644, 658 that are configured to receive one or more mechanical fasteners654 (e.g., screws, rivets, pins, clips, bolts, etc.). Additionally, oralternatively, it is envisioned that the bracket 642 may be welded oradhesively secured to the bumper beam 10, or that the bracket 642 mayinclude one or more attachment members (e.g., hooks or the like) thatare configured for engagement with corresponding receipt structures(e.g. eyelets, openings, or the like) included on (or formed in) thebumper beam 10.

Although the end walls 644, 658 and the side walls 646 i, 646 ii areillustrated as defining an equivalent (uniform) thicknesses T in theembodiment seen in FIG. 10, in alternate embodiments of the disclosure,it is envisioned that the thickness T of the front end wall 644, therear end wall 658, and/or the side walls 646 i, 646 ii may be varied.For example, the thicknesses T of the side walls 646 i, 646 ii may begreater than that of the front end wall 644 and/or the rear end wall 658to promote deformation of the bracket 642 in a particular manner. It isalso envisioned that one or more of the end walls 644, 658 and the sidewalls 646 i, 646 ii may include one or more weakened portions (e.g.,reliefs, openings, slits, etc.) to promote controlled deformation of thebracket 642.

FIG. 11 illustrates another embodiment of the energy absorber, which isidentified by the reference character 700. The energy absorber 700includes a front (first) absorption member 760A and a rear (second)absorption member 760B. The absorption members 760A, 760B are configuredas discrete structures and may be connected to each other, and to thebumper beam 10, in any suitable manner, such as, for example, throughthe use of one or more mechanical fasteners (e.g., screws, rivets, pins,clips, bolts, etc.) or adhesives, via welding, etc. Although shown asincluding two absorption members 760A, 760B in the embodiment seen inFIG. 11, it is envisioned that the number of absorption members 760 maybe increased in alternate embodiments of the disclosure.

In the illustrated embodiment, the absorption members 760A, 760B eachinclude a uniform, generally polygonal (e.g., rectangular or square)cross-sectional configuration. More specifically, the absorption member760A defines a width WA, a length LA, and a height HA, and theabsorption member 760B defines a width WB, a length LB, and a height HB,wherein the width WA is less than the width WB, the length LA is greaterthan the length LB, and the height HA is less than the height HB. Giventhe disparity in dimensions between the absorption members 760A, 760B,the absorption capabilities of the absorption member 760A differ fromthose of the absorption member 760B. It should be appreciated, however,that, in alternate embodiments, the particular configuration anddimensions of the absorption members 760A, 760B may be varied withoutdeparting from the scope of the present disclosure. For example,depending upon the configuration of the bumper beam 10, spatialrequirements, packaging concerns, etc., it is envisioned that theabsorption members 760A, 760B may be identical in configuration anddimensions, or that one or more of the absorption members 760A, 760B mayinclude an irregular cross-sectional configuration (e.g., an L-shapedconfiguration, as discussed above in connection with the energy absorber300 seen in FIG. 6).

In certain embodiments, it is envisioned that the absorption members760A, 760B may include (e.g., may be formed from) the same material,which may include any suitable metallic materials (e.g., aluminum,steel, etc.) and/or non-metallic materials (e.g., foam, polymericmaterials, plastic materials, etc.), either individually or incombination. Alternatively, it is envisioned that the absorption members760A, 760B may include different materials. For example, in theparticular embodiment seen in FIG. 11, the absorption member 760A isformed from a foam having a density of 10 pcf or higher, such asexpanded polypropylene foam, and the absorption member 760B is formedfrom aluminum. To assemble and connect the energy absorber 700 to thebumper beam 10, the absorption member 760B is welded (or otherwisesecured) to the bumper beam 10, and the absorption member 760A isadhesively secured to the absorption member 760B.

In various embodiments of the disclosure, to vary the absorptioncapabilities of the energy absorber 700, it is envisioned that theabsorption members 760A, 760B may be either solid in construction, orthat the absorption members 760A, 760B may define open interior spacesor cavities. For example, it is envisioned that either or both of theabsorption members 760A, 760B may include an internal honeycombstructure.

FIGS. 12-14 illustrate another embodiment of the energy absorber(identified by the reference character 800) shown in association withthe front-end of a vehicle Vi. In the illustrated embodiment, inaddition to the bumper beam 10 and the electronic sensor 12, thefront-end of the vehicle Vi includes a body component 26, which may beconfigured as an additional structural element, fascia, a supplementalshock absorber, etc. The energy absorber 800 is configured incorrespondence with the front-end of the vehicle Vi so as to define acontour that approximates (or matches) those defined by the bumper beam10 and the body component 26. More specifically, in the illustratedembodiment, the energy absorber 800 includes an upper (first) portion862A, and a lower (second) portion 862B that is positioned verticallybeneath the upper portion 862A, and a bridge portion 864 that extendstherebetween. As discussed in connection with the preceding embodiments,the energy absorber 800 is positioned in general alignment with theelectronic sensor 12 so as to facilitate absorption of the force F (FIG.2) applied to the vehicle Vi during a low-force impact, and therebyprotect the electronic sensor 12 and guard against dislocation.

The upper portion 862A includes a rear (first) end wall 866A and a front(second) end wall 868A, which extend in generally parallel relation tothe front end face 18 of the bumper beam 10 (e.g., to the forward-mostvertical surface thereof). The lower portion 862B includes a front endwall 868B, and is connected to the upper portion 862A by the bridgeportion 864. Although the bridge portion 864 is shown as extending fromthe upper portion 862A at an obtuse angle β (FIG. 13) in FIGS. 12-14, inalternate embodiments of the disclosure, it is envisioned that thebridge portion 864 may be oriented in generally orthogonal relation tothe upper portion 862A (and the lower portion 862B) (i.e., such that theangle β is approximately 90°). The bridge portion 864 is configured andpositioned such that the upper portion 862A and the lower portion 862Bare located at different positions along the length of the vehicle Vi(i.e., such that the lower portion 862B is positioned forwardly of theupper portion 862A), whereby the energy absorber 800 includes anirregular, stepped cross-sectional configuration that allows the energyabsorber 800 to cloak or otherwise cover the bumper beam 10 and the bodycomponent 26.

As discussed above in connection with the preceding embodiments, theenergy absorber 800 may be formed from any suitable metallic ornon-metallic materials, either exclusively or in combination. Forexample, in the embodiment seen in FIGS. 12-14, the energy absorber 800is formed from the aforedescribed expanded polypropylene foam. Althoughshown as being of monolithic construction in FIGS. 12-14 (i.e., suchthat the upper portion 862A, the lower portion 862B, and the bridgeportion 864 are integrally formed), such as via injection molding, forexample, in alternate embodiments of the disclosure, it is envisionedthat the upper portion 862A, the lower portion 862B, and/or the bridgeportion 864 may be formed as separate, discrete structures. In suchembodiments, the upper portion 862A, the lower portion 862B, and thebridge portion 864 may be connected in any suitable manner, such as, forexample, through the use of mechanical fasteners (e.g., screws, rivets,pins, clips, bolts, etc.), adhesives, etc.

To further enhance the absorption capabilities of the energy absorber800, it is envisioned that the energy absorber 800 may include one ormore supplemental absorption members 870. In the embodiment illustratedin FIGS. 12-14, for example, the supplemental absorption members 870 areillustrated as being connected to (or formed integrally with) the frontend wall 868B of the lower portion 862B. It should be appreciated,however, that the particular location (and configuration) of thesupplemental absorption member(s) 870 may be varied in alternateembodiments of the energy absorber 800, depending, for example, upon theconfiguration of the bumper beam 10, the configuration of the bodycomponent 26, spatial requirements, packaging concerns, etc.Additionally, although shown as being formed from the same material asthe upper portion 862A, the lower portion 862B, and the bridge portion864, and as being integrally formed therewith, in alternate embodiments,it is envisioned that the absorption member(s) 870 may be formed asseparate, discrete structures, and that the absorption member(s) 870 mayinclude (e.g., may be formed from) one or more different materials. Insuch embodiments, the absorption member(s) 870 may be connected to theupper portion 862A, the lower portion 862B, and/or the bridge portion864 in any suitable manner, such as, for example, through the use ofmechanical fasteners (e.g., screws, rivets, pins, clips, bolts, etc.),adhesives, etc.

The energy absorber 800 may be secured or otherwise connected to thefront-end of the vehicle Vi (e.g., to the bumper beam 10 and/or the bodycomponent 26) in any manner described hereinabove in connection with thepreceding embodiments. For example, the energy absorber 800 may beadhesively secured to the bumper beam 10 and/or the body component 26.Additionally, or alternatively, an attachment member 872 may be utilizedto connect the energy absorber 800 to the vehicle Vi. In the embodimentseen in FIGS. 12-14, for example, the attachment member 872 isconfigured as a metallic brace 874 that extends between, and is securedto, the bumper beam 10 (or other such suitable structure on the vehicleVi) and the energy absorber 800. It is envisioned that the brace 874 maybe secured to the vehicle Vi and the energy absorber 800 in any suitablemanner. For example, the brace 874 may be welded to the bumper beam 10(or integrally formed therewith), and may be secured to the energyabsorber 800 using one or more mechanical fasteners 876 (e.g., screws,rivets, pins, clips, bolts, etc.).

Although shown as being generally planar in the embodiment seen in FIGS.12-14, it should be appreciated that the particular configuration of theattachment member 872 may be varied in alternate embodiments of thedisclosure. For example, the attachment member 872 may include one ormore projections that extend from the bumper beam 10 (or other suchsuitable structure on the vehicle Vi) for insertion into the energyabsorber 800 (e.g., into one or more corresponding openings) such thatthe projections are concealed by the energy absorber 800.

Persons skilled in the art will understand that the various embodimentsof the disclosure described herein and shown in the accompanying figuresconstitute non-limiting examples, and that additional components andfeatures may be added to any of the embodiments discussed hereinabovewithout departing from the scope of the present disclosure.Additionally, persons skilled in the art will understand that theelements and features shown or described in connection with oneembodiment may be combined with those of another embodiment withoutdeparting from the scope of the present disclosure and will appreciatefurther features and advantages of the presently disclosed subjectmatter based on the description provided. Variations, combinations,and/or modifications to any of the embodiments and/or features of theembodiments described herein that are within the abilities of a personhaving ordinary skill in the art are also within the scope of thedisclosure, as are alternative embodiments that may result fromcombining, integrating, and/or omitting features from any of thedisclosed embodiments. For example, although generally discussed in thecontext of the front-end of the vehicle V (FIG. 1) herein, as mentionedabove, it should be appreciated that any of the various embodiments ofthe presently disclosed energy absorber may be utilized in the rear-endof the vehicle V as well.

Use of broader terms such as “comprises,” “includes,” and “having”should be understood to provide support for narrower terms such as“consisting of,” “consisting essentially of,” and “comprisedsubstantially of.” Accordingly, the scope of protection is not limitedby the description set out above but is defined by the claims thatfollow and includes all equivalents of the subject matter of the claims.

In the preceding description, reference may be made to the spatialrelationship between the various structures illustrated in theaccompanying drawings, and to the spatial orientation of the structures.However, as will be recognized by those skilled in the art after acomplete reading of this disclosure, the structures described herein maybe positioned and oriented in any manner suitable for their intendedpurpose. Thus, the use of terms such as “above,” “below,” “upper,”“lower,” “inner,” “outer,” “left,” “right,” “upward,” “downward,”“inward,” “outward,” etc., should be understood to describe a relativerelationship between the structures and/or a spatial orientation of thestructures. Those skilled in the art will also recognize that the use ofsuch terms may be provided in the context of the illustrations providedby the corresponding figure(s).

Additionally, terms such as “approximately,” “generally,”“substantially,” and the like should be understood to allow forvariations in any numerical range or concept with which they areassociated. For example, it is intended that the use of terms such as“approximately” and “generally” should be understood to encompassvariations on the order of 25%, or to allow for manufacturing tolerancesand/or deviations in design.

Each and every claim is incorporated as further disclosure into thespecification and represents embodiments of the present disclosure.Also, the phrases “at least one of A, B, and C” and “A and/or B and/orC” should each be interpreted to include only A, only B, only C, or anycombination of A, B, and C.

What is claimed is:
 1. A vehicle, comprising: a bumper assemblyincluding an end face and opposing sidewalls extending axially forwardfrom the end face along a length of the vehicle such that the end faceand the sidewalls collectively define an upwardly facing opening; anelectronic sensor fixed in relation to the bumper assembly; and anenergy absorber located in the upwardly facing opening defined by thebumper assembly and connected to the end face of the bumper assembly ingeneral alignment with the electronic sensor, the energy absorber beingconfigured and positioned to protect the electronic sensor and reducedislocation of the electronic sensor by absorbing energy resulting froma low-force impact between the vehicle and an external object.
 2. Thevehicle of claim 1, wherein the energy absorber is connected to an endface of the bumper assembly such that the energy absorber is positionedoutwardly of the electronic sensor.
 3. The vehicle of claim 1, whereinthe electronic sensor and the energy absorber each define a widthextending in generally parallel relation to the bumper assembly, thewidth of the energy absorber being greater than or equal to the width ofthe electronic sensor.
 4. The vehicle of claim 1, wherein the energyabsorber includes a foam having a density greater than 10 pcf.
 5. Avehicle, comprising: a bumper assembly defining an end face andsidewalls defining an upwardly facing opening; an electronic sensorfixed in relation to the bumper assembly; and an energy absorberconnected to the end face of the bumper assembly within the upwardlyfacing opening such that the energy absorber is positioned outwardly ofand vertically below the electronic sensor along a length of the vehiclesuch that the energy absorber and the electronic sensor are spacedvertically from each other, the energy absorber being positioned ingeneral alignment with the electronic sensor and including a foam bodyconfigured and positioned to absorb energy during a low-force impactbetween the vehicle and an external object to protect the electronicsensor and reduce dislocation of the electronic sensor.
 6. The vehicleof claim 5, wherein the electronic sensor and the energy absorber eachdefine a width extending in generally parallel relation to the bumperassembly, the width of the energy absorber being greater than or equalto the width of the electronic sensor.
 7. The vehicle of claim 5,wherein the foam body includes an expanded polypropylene foam having adensity greater than 10 pcf.
 8. A method of protecting an electronicsensor in a vehicle during a low-force impact between the vehicle and anexternal object, the method comprising: securing an energy absorber toan end face of a bumper assembly of the vehicle such that the energyabsorber is positioned outwardly of the electronic sensor and in generalalignment with the electronic sensor within an upwardly facing openingdefined by the end face and opposing sidewalls extending forwardly fromthe end face, the energy absorber defining a width extending ingenerally parallel relation to the bumper assembly greater than or equalto a width of the electronic sensor.
 9. The method of claim 8, whereinsecuring the energy absorber to the bumper assembly includes positioninga foam body of the energy absorber vertically below the electronicsensor.
 10. The vehicle of claim 1, wherein the bumper assembly includesa vertical portion and a horizontal portion extending forwardly from thevertical portion such that the bumper assembly includes a generallyL-shaped vertical cross-sectional configuration.
 11. The vehicle ofclaim 1, wherein the energy absorber is positioned eccentricallyrelative to the bumper assembly.
 12. The vehicle of claim 11, whereinthe bumper assembly and the energy absorber are configured such that afirst lateral end of the bumper assembly and a corresponding firstlateral end of the energy absorber define a first distance therebetweenand second lateral end of the bumper assembly and a corresponding secondlateral end of the energy absorber define a second distance therebetweengreater than the first distance.
 13. The vehicle of claim 1, wherein theenergy absorber includes a housing defining lateral supports withapertures configured to receive mechanical fasteners to thereby securethe energy absorber to the bumper assembly.
 14. The vehicle of claim 13,wherein the housing defines a first lateral support and a second lateralsupport vertically offset from the first lateral support.
 15. Thevehicle of claim 5, wherein the bumper assembly includes a generallyL-shaped cross-sectional configuration.
 16. The vehicle of claim 5,wherein the energy absorber is positioned eccentrically relative to thebumper assembly.
 17. The vehicle of claim 16, wherein the bumperassembly and the energy absorber are configured such that a firstlateral end of the bumper assembly and a corresponding first lateral endof the energy absorber define a first distance therebetween and secondlateral end of the bumper assembly and a corresponding second lateralend of the energy absorber define a second distance therebetween greaterthan the first distance.
 18. The method of claim 8, wherein securing theenergy absorber includes securing the energy absorber to a verticalportion of the bumper assembly such that a horizontal portion of thebumper assembly extends forwardly of the energy absorber.
 19. The methodof claim 8, wherein securing the energy absorber includes positioningthe energy absorber eccentrically relative to the bumper assembly. 20.The method of claim 19, wherein positioning the energy absorbereccentrically relative to the bumper assembly includes positioning theenergy absorber such that a first lateral end of the bumper assembly anda corresponding first lateral end of the energy absorber define a firstdistance therebetween and second lateral end of the bumper assembly anda corresponding second lateral end of the energy absorber define asecond distance therebetween greater than the first distance.